JP2006192828A - Manufacturing equipment of continuous, laminated sheet of thermoplastic resin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide manufacturing equipment (1) capable of stably manufacturing a continuous, laminated sheet (A) of a thermoplastic resin in which a continuous film (F) of the thermoplastic resin is sufficiently firmly stuck to a continuous sheet (S) of the thermoplastic resin by heat fusion. <P>SOLUTION: This manufacturing equipment (1) is equipped with a die (3) which continuously extrudes a heated, molten thermoplastic resin (P) into a sheet form to form the continuous sheet (S); heating means (5) which independently heat the side portions (S1, S2) of the laminating face (Sa) of this continuous sheet (S) from the vicinity (S0) of the center line; and a laminating means (2) by which the continuous film (F) is superposed on the laminating face (Sa) heated as above, pressurized, subjected to heat fusion and laminated. By continuously extruding the thermoplastic resin (P) from the die (3) into the shape of a sheet, heating independently the side portions (S1, S2) of the laminating face (Sa) of this continuous sheet from the vicinity (S0) of the center line, then placing the continuous film (F) thereon, pressurizing and performing heat fusion, there can be manufactured the continuous, laminated sheet (A). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

The present invention relates to an apparatus for producing a thermoplastic resin continuous bonding sheet, and more specifically, for producing a thermoplastic resin continuous bonding sheet in which a thermoplastic resin continuous film is bonded to a thermoplastic resin continuous sheet by thermal fusion. Relates to the device.

As shown in FIG. 4, a thermoplastic resin continuous sheet [hereinafter sometimes abbreviated as a continuous sheet. ] (S) on one side [FIG. 4 (a)] or on both sides [FIG. 4 (b)], a thermoplastic resin continuous film [hereinafter sometimes abbreviated as continuous film]. ] (F) is a thermoplastic resin continuous bonding sheet bonded by thermal fusion [hereinafter sometimes referred to as a continuous bonding sheet. As an apparatus (1) for producing (A), Patent Document 1 (Japanese Patent Laid-Open No. 6-126854) discloses a continuous melted thermoplastic resin (P) as shown in FIG. Without heating the continuous sheet (S) extruded from the die (3) and the continuous sheet (S) extruded from the die (3), the continuous film (F) is applied to the bonding surface (Sa) of the continuous sheet (S). A manufacturing apparatus (1) including a pair of laminating rolls (21, 22) for laminating, pressing and laminating) is disclosed. According to the conventional manufacturing apparatus (1), since the continuous sheet (S) immediately after being extruded from the die (3) is still in a heated state, the bonding roll ( The continuous film (F) can be bonded by heat sealing according to 21 and 22) to produce the desired continuous bonding sheet (A).

However, in such a conventional manufacturing method, even if the continuous film (F) is not necessarily bonded or bonded, the continuous bonded sheet (A) after bonding is cut with, for example, a rotating circular saw, There was a problem that the continuous film (F) was easily peeled near the cut surface.

JP-A-6-126854

Therefore, the present inventor has developed a production apparatus (1) capable of stably producing a continuous laminated sheet (A) in which the continuous film (F) is sufficiently firmly bonded to the continuous sheet (S) by heat fusion. As a result of intensive studies, the side portions (S1, S2) of the continuous sheet (S) are easier to cool than the centerline vicinity portion (S0), and the laminating is performed at a relatively low temperature. By heating the part (S1, S2) independently from the centerline vicinity part (S0) and then bonding, it is possible to stably produce a continuous bonding sheet (A) bonded with sufficient strength. The headline, the present invention has been reached.

That is, the present invention is a thermoplastic resin continuous sheet (S), a thermoplastic resin continuous film in which a thermoplastic resin continuous film (F) heat-bondable to the thermoplastic resin continuous sheet is bonded by thermal fusion. It is an apparatus (1) for producing a bonding sheet (A),
A die (3) to continuously extrude the thermoplastic resin (P) that has been heated and melted into a sheet to obtain a thermoplastic resin continuous sheet (S);
Heating means (5) for independently heating the side portions (S1, S2) of the bonding surface (Sa) of the thermoplastic resin continuous sheet (S) extruded from the die (3) from the vicinity of the center line (S0). )When,
Bonding means (2) for laminating and pressing the thermoplastic resin continuous film (F) on the laminating surface (Sa) heated by the heating means (5) and thermally fusing and laminating. The apparatus (1) for producing the thermoplastic resin continuous pasting sheet (A) is provided. 1 and 2 schematically show an example of the production apparatus (1) of the present invention.

According to the production apparatus (1) of the present invention, the thermoplastic resin (P) heated and melted is continuously extruded from the die (3) into a sheet to obtain a thermoplastic resin continuous sheet (S),
After heating the side part (S1, S2) of the bonding surface (Sa) of the thermoplastic resin continuous sheet (S) independently from the centerline vicinity part (S0),
The thermoplastic resin continuous film (F) can be laminated and pressed on the bonding surface (Sa), and heat bonded and bonded to produce a thermoplastic resin continuous film (A). .

According to the production apparatus (1) of the present invention, it is easy to set the bonding surface (Sa) of the continuous sheet (S) to a temperature suitable for bonding by thermal fusion, so that the continuous sheet can be stably and continuously. The continuous continuous sheet (A) can be produced by sufficiently and firmly bonding the continuous film (F) to (S) by heat sealing.

Hereinafter, the production apparatus (1) of the present invention will be described in detail with reference to FIGS. 1 and 2 schematically show an example of the production apparatus (1) of the present invention. FIG. 3 schematically shows a top view of an example of the heating means (5) applied to the manufacturing apparatus (1). In FIG. 4, the layer structure of the continuous bonding sheet | seat (A) manufactured with the manufacturing apparatus (1) of this invention is shown typically.

The production apparatus (1) of the present invention is an apparatus (1) for producing a thermoplastic resin continuous laminated sheet (A) in which a thermoplastic resin continuous film (F) is laminated to a thermoplastic resin continuous sheet (S). ). The thermoplastic resin continuous sheet (S) is a continuous sheet made of a thermoplastic resin. Examples of the thermoplastic resin constituting this are acrylic resin, styrene resin, methyl methacrylate-styrene copolymer resin, polycarbonate Resin, acrylonitrile-butadiene-styrene copolymer resin (ABS resin), acrylonitrile-styrene copolymer resin (AS resin), olefin resin such as vinyl chloride resin, polyethylene, polypropylene, polyester resin, polyacetal resin, polyvinylidene fluoride ( PVDF) resin and the like, and nylon resin. Such a thermoplastic resin may contain additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent. Moreover, you may contain the elastic body particle.

Such a continuous sheet (S) is obtained, for example, by continuously extruding a thermoplastic resin (P) that has been heated and melted into a sheet by an extrusion molding method, as shown in FIGS. The manufacturing apparatus (1) of the present invention shown in FIGS. 1 and 2 includes a die (3) that continuously extrudes a heat-melted thermoplastic resin (P) into a sheet to form a continuous sheet (S). Yes.

In order to heat and melt the thermoplastic resin (P), an extruder (7) is usually used, and the thermoplastic resin (P) is kneaded while being heated by the extruder (7). P) enters a molten state and is sent to the die (3).

The heat-melted thermoplastic resin (P) is continuously extruded from the die (3) into a sheet shape, thereby forming a continuous sheet (S). As the die (3), for example, a T die can be used. The die (3) may be formed by extruding the thermoplastic resin (P) as a single layer, or may be formed by extruding in two or more layers. By using a die that extrudes in a single layer, a single-layer continuous sheet (S) is formed. A multilayer continuous sheet (S) is formed by coextrusion of two or more thermoplastic resins using a die that is extruded in multiple layers.

The continuous sheet (S) extruded from the die (3) may be sent to the heating means (5) as it is and heated, or as shown in FIGS. 1 to 2, rolling rolls (41, 42, 43 ) And then sent to the heating means (5) to be heated. The diameter of the rolling rolls (41, 42, 43) used when rolling with a rolling roll is usually about 15 cm to 60 cm. The number of rolling rolls is not particularly limited as long as it is two or more so that the continuous sheet (S) can be sandwiched and rolled, but in the production apparatus (1) shown in FIGS. 1 to 3, three rolling rolls (41, 42) are used. 43). In this production apparatus (1), the continuous sheet (S) extruded from the die (3) is first sandwiched between the first rolling roll (41) and the second rolling roll (42) and rolled. While being wound around the second rolling roll (42), it is further rolled by being sandwiched between the second rolling roll (42) and the third rolling roll (43). Immediately after being extruded from the die (3) or immediately after being rolled in the rolling rolls (41, 42, 43), the continuous sheet (S) is in a heated state, and the temperature (Ts) of the bonding surface (Sa) is Generally, it is in the range of ± 20 ° C. with respect to the glass transition temperature (Tgs) of the bonding surface (Sa).

The thickness of the continuous sheet (S) is usually about 1 mm to 20 mm, and the width is usually about 500 mm to 2500 mm.

The thermoplastic resin continuous film (F) used in the production method of the present invention is a continuous film made of a thermoplastic resin, and is usually a thermoplastic resin wound up on a raw roll (F1). A continuous film is used. As the thermoplastic resin constituting the continuous film (F), for example, as described above in the thermoplastic resin sheet (S), acrylic resin, styrene resin, methyl methacrylate-styrene copolymer, polycarbonate resin, ABS resin, Examples include vinyl chloride resin, polyolefin resin, polyester resin, polyacetal resin, fluororesin, and nylon resin.

The continuous film (F) may contain additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent. Moreover, you may contain the elastic particle. The continuous film (F) containing elastic particles is usually preferably used because it is excellent in flexibility and easy to handle. Examples of the elastic particles include acrylate copolymer resin particles, polybutadiene rubber particles, styrene-butadiene copolymer rubber particles, and butadiene-acrylate copolymer rubber particles.

The continuous film (F) may be a single layer film composed of a single layer or a multilayer film having a structure in which two or more layers are laminated. The thickness of the continuous film (F) is usually thinner than the continuous sheet (S), usually about 50 μm to 1000 μm, and the width is the same as that of the continuous sheet (S).

For the continuous film (F), a material that is heat-fusible to the continuous sheet (S), that is, a material that can be bonded to the continuous sheet (S) by heat sealing, for example, the bonding surface (Fa) is used. A film (F) made of the same material as the bonding surface (Sa) of the continuous sheet is used. Further, when the bonding surface (Sa) of the continuous sheet (S) is an acrylic resin or methyl methacrylate-styrene copolymer resin, the bonding surface (Fa) is an acrylic resin, methacrylic resin as the continuous film (F). Those made of acid methyl-styrene copolymer resin, styrene resin, ABS resin, fluororesin, nylon resin and the like are used. The continuous film (F) may be subjected to a surface treatment on the bonding surface (Fa) so as to be easily heat-sealed with the continuous sheet (S).

In the continuous film (F), a surface treatment layer (Fh) may be provided on the non-bonding surface (Fb) opposite to the bonding surface (Fa) bonded to the continuous sheet. As the surface treatment layer (Fh), for example, a hard coat layer for improving the surface hardness, a anti-reflection layer for reducing the reflectance of visible light on the surface, an anti-glare layer for imparting anti-glare properties, light of a specific wavelength 2 or more types of surface treatment layers between the surface treatment layer and the continuous film, or between the surface treatment layer and the continuous film In the case of using, an adhesion layer for improving adhesion between these surface treatment layers can be mentioned. The thickness of the surface treatment layer (Fh) is usually about 0.1 μm to 50 μm.

The hard coat layer is usually provided as a single layer, and examples thereof include a cured layer obtained by polymerizing and curing a polyfunctional monomer as a main component. Specifically, polyfunctional polymerizable compounds containing two or more acryloyl groups or methacryloyl groups such as urethane acrylate, polyester acrylate, polyether acrylate, urethane methacrylate, polyester methacrylate, polyether methacrylate, etc. Examples thereof include a cured layer obtained by polymerization and curing using an activation energy ray such as a cured layer, and a cured layer obtained by crosslinking and curing a layer made of a silicon-based, melamine-based, or epoxy-based crosslinkable resin material. Among them, a cured layer obtained by polymerizing and curing urethane acrylate and a cured layer obtained by crosslinking and curing a layer made of a silicon-based crosslinkable resin material are excellent in terms of durability and ease of handling. The thickness of the hard coat layer is usually 1 μm to 20 μm.

The anti-reflection layer may be a single layer structure composed of a single low refractive index layer, or a two-layer structure composed of a high refractive index layer-low refractive index layer in order from the film (F) side, a medium refractive index layer-high A multilayer structure such as a three-layer structure composed of a refractive index layer-low refractive index layer and a four-layer structure composed of a high refractive index layer-low refractive index layer-high refractive index layer-low refractive index layer may be used. When providing the antireflection layer as the surface treatment layer (Fh), when providing other layers such as a hard coat layer, the other layer is usually composed of the antireflection layer and the continuous film (F). Between. Among these, a hard coat layer between the antireflection layer and the continuous film is preferable because the surface hardness is improved.

These surface treatment layers (Fh) can be provided by a normal coating method such as a wet coating method or a dry coating method, but the wet coating method is preferred in terms of productivity and cost, and among them, it can be formed continuously. Thus, it is preferably provided by a roll coating method.

A commercially available film can also be used as the continuous film (F) provided with the surface treatment layer (Fh), for example, an acrylic resin single layer provided with a low reflection layer (Fh) on the non-bonding surface (Fb). As the continuous film (F), “Realak 4700”, “Realak 4700S” and the like sold from Nippon Oil & Fats Co., Ltd. can be used.

The continuous film (F) may be bonded to one side of the continuous sheet (S) as shown in FIG. 1, or may be bonded to both sides of the continuous sheet (S) as shown in FIG.

The production apparatus (1) of the present invention includes a heating means (5) for heating the bonding surface (Sa) of the continuous sheet (S). This heating means (5) heats the side portions (S1, S2) of the bonding surface (Sa) independently from the centerline vicinity portion (S0). Specifically, for example, as shown in FIG. 3, heaters (H1, H2) are provided on the side portions (S1, S2) of the continuous sheet (S), respectively, and the bonding surface ( Sa) is heated.

Since the heaters (H1, H2) can heat the side portions (S1, S2) of the bonding surface independently from the centerline vicinity (S0), those heated by radiant heat such as an infrared heater are preferably used. Depending on the thickness of the continuous sheet (S), the type of thermoplastic resin constituting the bonding surface, and the absorption wavelength, for example, a short wavelength infrared heater, a medium wavelength infrared heater, a long wavelength infrared heater, and the like are appropriately selected. Used.

The shape of the heater (H1, H2) is, for example, the conveyance direction of the continuous sheet (S) so that the side portions (S1, S2) can be sufficiently heated independently without heating the vicinity of the center line (S0) It is preferably a rod shape, a rectangular shape, or the like that is long along (L) and short along the width direction (W).

The temperature of the bonding surface of the side portions (S1, S2) after being heated by the heaters (H1, H2) is preferably substantially equal to the vicinity of the center line (S0). For this purpose, for example, thermometers (T0 to T2) are arranged in the vicinity of the center line (S0) and the side parts (S1, S2) on the downstream side of the heaters (H1, H2). Based on the measured temperature of the bonding surface of the vicinity of the center line (S0) and side (S1, S2), the controller (not shown) that adjusts the heater output, etc. of the side (S1, S2) What is necessary is just to adjust the output of a heater (H1, H2) so that the temperature of a bonding surface may become equal to a centerline vicinity part (S0). As the thermometer (T0 to T2), a non-contact type that can be measured without touching the continuous sheet (S) such as a radiation thermometer is usually used.

The heaters (H1, H2) for heating the side parts (S1, S2) are configured so that the interval can be adjusted appropriately by a slide mechanism, etc. It is preferable that the continuous sheet (S) having a width can be easily adapted.

Such a heating means (5) should just heat the bonding surface (Sa) bonded with a continuous film (F), bonds a continuous film (F) on both surfaces, and is in FIG.4 (b). When obtaining a continuous laminated sheet (A) on which a continuous film (F) as shown is obtained, it is arranged on both sides of the continuous sheet (S) so that both sides can be heated as shown in FIG. Good. Moreover, when bonding on one side and obtaining a continuous bonding sheet (A) as shown to Fig.4 (a), as shown in FIG. 1, the bonding surface (Sa) bonded with a continuous film. It may be arranged only on one side, so that only the bonding surface (Sa), as well as the non-bonding surface (Sb) on the opposite side, can be heated. It may be arranged on both sides.

In the heating means (5), heaters (H3 to H5) are arranged further downstream in the conveying direction (L), and the continuous sheet (S) is further heated by the heaters (H3 to H5). It may be configured. The heater arranged on the downstream side may be a single sheet that heats the continuous sheet (S) over the entire surface, but is divided into a plurality of sections in the width direction so that it can be heated uniformly. 3 may be a heater that heats each section independently. In the heating means (5) shown in FIG. 3, the continuous sheet (S) is placed in the width direction (W) in the vicinity of the center line (S0) and the side. The heaters (H3 to H5) are divided into three sections (S1, S2) and heated independently for each section. Further, in the heating means (5) shown in FIG. 3, a thermometer (T3 to T5) is arranged on the downstream side in the transport direction of each heater (H3 to H5), and the controller ( The output of each heater (H3 to H5) is adjusted so that the temperature of the bonding surface (Sa) is uniform in the width direction (W).

While being heated by the heating means (5), the continuous sheet (S) is normally held flat by the holding mechanism (6). In the manufacturing apparatus (1) shown in FIGS. 1 and 2 as the holding mechanism (6), a plurality of guide rolls (6) arranged side by side on a horizontal plane are used. As this guide roll (6), what is marketed as a roller table, for example can be used. The continuous sheet (S) is conveyed while being held flat by the holding mechanism (6). Note that the continuous sheet (S) while being heated does not need to be held strictly flat, and may be held substantially flat so that no stress remains.

The laminating means (2) superposes and presses the continuous film (F) on the laminating surface (Sa) heated by the heating means (5), and heat-fuses and bonds. As the bonding means (2), a pair of bonding rolls (21, 22) is usually used. The laminating rolls (21, 22) may be configured to be driven to rotate and to take up the continuous sheet (S) as a take-up roll. It may be configured to be driven to rotate while being synchronized with the rolling roll (43) so as to be pulled without substantially applying a stretching force to the rolled continuous sheet (S). The bonding roll (21, 22) may be a metal roll whose surface is made of a metal material such as stainless steel, but is bonded to the continuous sheet of both sides of the continuous film (F). When the surface treatment layer (Fh) is provided on the non-bonding surface (Fb) opposite to the surface (Fa), especially on the non-bonding surface, the surface treatment layer (Fh) is not easily damaged. The bonding roll in contact with the continuous film (F) is preferably a rubber roll having a surface made of a rubber material. The diameters of the bonding rolls (21, 22) are usually about 5 cm or more and 30 cm or less, and the respective diameters are preferably equal to each other.

In the production apparatus (1) of the present invention, the heating means (5) heats the side portions (S1, S2) of the bonding surface (Sa) of the continuous sheet (S) independently from the centerline vicinity portion (S0). After that, by the laminating means (2), the continuous film (F) is superimposed on this laminating surface (Sa), pressed, and heat-sealed, so that it is extruded from the die (3) and continuously heated. Compared to the conventional manufacturing equipment that heats and heats the continuous film (F) without any heating of the sheet (S), the continuous film (F) is bonded sufficiently firmly. (A) can be manufactured.

It is a schematic diagram which shows an example of the manufacturing apparatus of the thermoplastic resin continuous bonding sheet | seat of this invention. It is a schematic diagram which shows another example of the manufacturing apparatus of the thermoplastic resin continuous bonding sheet | seat of this invention. It is a top view which shows typically the detail of the heating means in the manufacturing apparatus of this invention. It is a step figure which shows typically the layer structure of an example of the thermoplastic resin continuous bonding sheet | seat manufactured with the manufacturing apparatus of this invention. It is a schematic diagram which shows the manufacturing apparatus of the conventional thermoplastic resin continuous bonding sheet | seat.

Explanation of symbols

1: Manufacturing apparatus for thermoplastic resin continuous bonding sheet 2: Bonding means 21, 22: Bonding roll 3: Die
41-43: Rolling roll 5: Heating means H1-H5: Heater T0-T5: Non-contact thermometer 6: Holding mechanism (guide roll)
7: Extruder A: Thermoplastic resin continuous bonding sheet S: Thermoplastic resin continuous sheet
Sa: Bonding surface b: Non-bonding surface S1, S2: Side part S0: Centerline vicinity L: Conveyance direction W: Width direction F: Thermoplastic resin continuous film
Fa: Bonding surface Fb: Non-bonding surface Fh: Surface treatment layer F1: Raw roll

Claims (2)

Thermoplastic resin continuous sheet (S), a thermoplastic resin continuous laminated sheet (A) in which a thermoplastic resin continuous film (F) that is heat-fusible is bonded to the thermoplastic resin continuous sheet by thermal fusion. Is a device (1) for manufacturing
A die (3) to continuously extrude the thermoplastic resin (P) that has been heated and melted into a sheet to obtain a thermoplastic resin continuous sheet (S);
Heating means (5) for independently heating the side portions (S1, S2) of the bonding surface (Sa) of the thermoplastic resin continuous sheet (S) extruded from the die (3) from the vicinity of the center line (S0). )When,
Bonding means (2) for laminating and pressing the thermoplastic resin continuous film (F) on the laminating surface (Sa) heated by the heating means (5) and thermally fusing and laminating. An apparatus (1) for producing the thermoplastic resin continuous laminating sheet (A), comprising: Thermoplastic resin continuous sheet (S), a thermoplastic resin continuous laminated sheet (A) in which a thermoplastic resin continuous film (F) that is heat-fusible is bonded to the thermoplastic resin continuous sheet by thermal fusion. )
The thermoplastic resin (P) melted by heating is continuously extruded from the die (3) into a sheet to obtain a thermoplastic resin continuous sheet (S),
After heating the side (S1, S2) of the bonding surface (Sa) of the thermoplastic resin continuous sheet (S) independently from the centerline vicinity (S0),
The method for producing a thermoplastic resin continuous bonding sheet (A), characterized in that the thermoplastic resin continuous film (F) is superposed on the bonding surface (Sa) and pressed, and heat bonded and bonded. .

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